Box forming machine



Oct. 25, 1960 L. A. MEYER 2,957,395

BOX FORMING MACHINE Filed Oct. 9, 1956 4 Sheets-Sheet 1 Oct. 25, 1960 L. A. MEYER 2,957,395

BOX FORMING MACHINE Filed Oct. 9, 1956 4 Sheets-Sheet 2 Oct. 25, 1960 L. A. MEYER BOX FORMING MACHINE 4 Sheets-Sheet 3 Filed Oct. 9, 1956 Ocit. 25, 1960 L. A. MEYER 2,957,395

BOX FORMING MACHINE Filed. 0st. 9, 1956 4 Sheets-Sheet 4 INVENTOR.

Zazzzs A .JYgzr BQX FORMING MAQHINE Louis A. Meyer, 403 E. th St., Sterling, Ill.

Filed Oct. 9, 1956, Set. No. 614,882

9 Claims. (Cl. 9.3--4) This invention is concerned with boxesand the like, and more particularly with an automatic machinefor manufacturing said boxes.

Box forming machines in the past have commonly been -.either continuousmotion machines, or intermittent moinstances have not allowed sufficient time for glue to set properly.

It is an object of this invention to provide a box form- .ing machine incorporating many of the advantages of both continuous motion and intermittent motion box forming machines.

More specifically, it is an object of this invention to provide a machine wherein a conveyor operates continuously, but a blankor partially completed box moves intermittently thereon.

In addition, it is an object of-this invention to provide a box forming machine wherein the conveyor moves continuously, 'but ample time is provided for the setting .of

:glue.

Furthermore, it is an object of this invention to provide .a .machine for forming boxes having double sidewalls,

double end walls, and reinforcing tabs, which machine is .of extraordinarily simple construction.

Other and further objects and advantages .of the present invention will be apparent from the following description when'taken in connection with the accompanying-drawings wherein:

Fig. l is an elevational view of a machine embodying the principles of the invention;

Fig. 2 is a plan view thereof;

Fig. 3 is aplan view of a blank used for 'fo rmingabox;

Fig. 4 is a perspective view of a completed box;

Fig. 5 is a vertical sectional view taken substantially along the line 5-5 in Fig. 1;

Fig. 6 is a view similar to Fig. 5 showing the parts in aditferent position of operation;

Fig. 7 is a vertical sectional view taken substantially along the line 7-7 in Fig. 1;

Fig. 8 is a vertical sectional view taken substantially along the line 8-8 in Fig. 1;

.Fig. 9 is a perspective view of certain of the mechanism at the final stage or station;

Fig. 10 is a similar viewshowing further mechanism at this station;

Fig. 11 is another view showing additional mechanism .at the final station;

'Fig. 12 shows a final operation at the final station;

"Fig. 13 is a vertical sectional view taken .substantially along the line 13-13 in Fig. 2;

Fig. 14 is a view similar to Fig. 13 and showing'the parts in a different position of operation;

tabs or corners.

' 2,557,395 Patented Oct. 25, 1-960 in a different position of operation.

Before referring to the machine in greater detail, it is thought that it would be helpful to refer first to Figs. 3 and 4, showing the blank, and the box, respectively. The blank comprises a fiat stamped out section of cardboard, and is identified by the numeral 20. As will be appreciated, the principles of the invention are equally applicable to other materials, and the blank could be made of plastic, for instance and could even be made of metal, and spot welded, rather than glued. However, the blank contains a rectangular bottom section 22, with a pair of rectangular sidewalls 24 along the opposite longitudinal edges thereof. The sidewalls are provided along their outer longitudinal edges with rectangular flaps 26, and'end-tabs28 are provided on the opposite ends of the sidewalls.

The blank 20 is further provided at its opposite ends with end walls 30, and end flaps 32 are provided on the end walls. Glue is spotted on the sidewalls, on the end 'walls, and on the end flaps along the dark areas indicated at 34, in a manner hereinafter to be set forth.

When the blank has been completely folded to its final shape, it resultsin a box 36 shown in Fig. 4, which box has double sidewalls, double end walls, and reinforcing The particular dimensions of the box depend on the final requirements, and the machine is adjustable, and is adapted to accommodate any of a great number of sizes of blanks, to produce boxes of corresponding size.

journalled on suitable shafts supported from side frame qmembers 52 in-suitable bearings, whereby the shafts are driven by a common chain 54 engaging driving sprockets on all 'ofthe shafts, the sprockets 50 therebyrotating with .theshafts'to drive the series of chains 40-48. Each of this group of chains is provided with a single lug 56, although it is within the comtemplation of the invention that greater numbers of lugs might be used.

Referring now in greater particularity to the machine, and first to Figs. 1 and 2, there will be seen a magazine 57 supporting astack of the blanks 20 above the chain-40. The magazine is provided with edge discharged slot or opening 58 at its bottom rightcorner, and the lug '56 is adapted -topick up'a blank once for each revolution or complete @cycle of the chain 40, and to slide the blank from the magazine beneath a glue roller so. The glue roller .60 is of a well known type having properly raised or embossed portions thereon for distributing glue on the areas 34. The glue roller 60 receives glue from an intermediate roller 62, which in turn receives the glue from a pickup roller 64 rotating in a container 66 having glue 68 therein. It will be understood that suitable means is provided for heating the container 66 when a glue of a type requiring heating is used.

The magazine and glue parts comprise a station hereinafter identified generally by the letter A, and the lug 56 pushes the glued blank onto the chain 42 at station B.

The blank 20 comes to a rest above the chain 42 after being left by the lug 56 on the chain 44}, and is not picked up by the lug on the chain 422 for some time. Meanwhile, the side flaps are folded toward the sidewalls-by means shown generally in Fig. l, and somewhat more specifically in Figs. 5 and 6. The blank 20 preferably is prescorecl as indicated by the dashed lines .at 70 in Fig. 3,

and also shown in various sectional views through the 3 blank, such as in Figs. 5 and 6. A hinged plate 72 on each side of the blank (there being two such plates) hinged at 74 onto fixed supports 76, which for example might be secured to a fixed part of the machine frame such as the side rails 52, or the blank supporting rails or track 38. The plates 72 are actuated by a connecting rod 78, which might be actuated, for example, by a roller 80 engaging a cam 82 driven by an auxiliary sprocket engaging the master chain 54, for example. Conveniently, the connecting rod 78 is provided with a hinged section 84 at the top thereof, and spring biased by a spring 86, whereby upon upward movement of the connecting rod the plate 72 will be moved from its normal horizontal position up through the angular position of Fig. 5 to the final position of Fig. 6. This folds the side flaps (since the action is by two plates, one on each side). The flap 26 is brought toward the sidewall 24, but not in contact therewith. The bend is slightly greater than a right angle, at the score line 70, in order to over break the flap, so that it will not tend to return to its initial position.

Fixed back-up or hold-down plates 90 preferably are provided and engage the blank between the flaps 26 and sidewalls 24 along the score lines 70 to insure folding or bending of the blanks along the score lines, and also to insure against the blanks moving upwardly as the plates 72 are pivotally moved upwardly.

The lug 56 on the chain 42 then picks up the partially folded blank and then moves it to station C, above chain 44. The blank again comes to rest, and by this time the glue 34 has had sufficient time to set that it will make a firm seal when the side flap is folded down against the sidewall on each side. As is shown in Fig. Sanother hinge plate 92, normally in vertical position, and hinged at 94 to a fixed support 96 is actuated from the side by a connecting rod 98, for example, by a cam 100 at the top of a shaft 102 operated by a suitable gearing and shafting 104 from a sprocket engaging the main or master chain 54. At this station, indicated at station C, the side flap 26 is folded down fiat against the sidewall 24 to which it is secured by the glue stripe or spot 34. When the blank is picked up by the lug 56 on the chain 44, the blank is carried between rollers 106 as in Fig. 7, thus to press the side flap 26 against the side wall 24 so that the glue will adhere the two together firmly.

The blank is passed on by the lug 56 on the chain 44 to station D above the chain 46. Station D is not illustrated in detail, since it is substantially identical with station B, exceptthat the side hinge plates 108 are somewhat closer together so as to fold the sidewalls in, in the same manner that the side flaps were folded at station B. Specifically, the sidewalls are somewhat over broken along the sidewall score lines 70. In other words, they are both folded beyond a right angle so that they will tend to extend upwardly substantially vertical.

The lug 56 on the chain 46 picks up the blank and moves it on to the final station, station E, at which point the blank comes to a halt, and has the finishing operations performed thereon. The first operation that occurs at station E is shown in Fig. 9. Bar or strap tuckers 110 are mounted on vertical shafts 112 journalled in suitable support means 114. Mechanism of any well known type, such as the double screw or worm, is provided for adjustment of the support means to move the shafts 112 towards and away from one another to accommodate blanks or boxes of different widths. The shafts 112 are pivoted in suitable time relation, by any satisfactory means such as cam followers 116 and cams 118, and pivot the tuckers 110 from a position substantially parallel to the line of motion of the blanks to slightly beyond a right angle position so that the end tabs 28 will be in the confronting relation shown in Fig. 9. Fixedly supported bars 120 at station E hold the double sidewalls in erect position as shown in Fig. 9 during the various operations performed on the blank at station E.

The next operation at station E is illustrated in Fig.

10. As shown in Fig. 10, horizontal shaft means 122 is provided at the front edge of the box, and also at the back edge. Pivotal flippers or plate means 124 are mounted on the shaft 122, and normally are in substantially horizontal position. The two flippers illustrated function as a unit, but preferably do not comprise a single plate due to the necessity for providing clearance for the sprocket chain and supporting rails along the center line of the box. These flippers swing to a vertical position to place the end walls up against the tabs 28.

During all of the operations at station E the blank 20 is held down as is shown in Figs. 13-16. More specifically, an overhead plate or support 126 is held by connecting rods 128 for vertical reciprocation. A post 130 extends downwardly from the center of the plate 126, and is telescopically received in a cylinder or sleeve 132 having a spring 134 compressed therein. A hold-down plate 136 is provided at the bottom of the cylinder 132. The blank 20 slides in beneath the plate 136, which need not be of very large area, and is held down resiliently by the force of the spring 134. During subsequent operation when the plate 126 is lowered by movement of the support or connecting rods 128 down through their guides 138 (which, incidentally, limit the upper position of the plate 126) the post 130 and cylinder 132 telescope, with the spring 134 compressing to a greater extent.

Reference should be had to Figs. 11, 13 and 14 for the penultimate operation on the box blank. A relatively large sun gear 140 is rotatably journalled on an arm 142 upstanding from the machine frame. A connecting rod 144 is secured to the gear for rotation thereof, and may be actuated by suitable means such as a hydraulic or pneumatic cylinder 146. An arm 148 is mounted coaxially with the sun gear 140, and extends radially there from. This arm is rotatable independently of the sun gear 140. A relatively small planet gear 150 is fixed on a shaft 152 and pivotally mounted at the end of the arm 148, the planet gear 150 meshing with the sun gear 140. A flap folding arm 154 is secured at the center line of the machine on the shaft 152, and conveniently has an inwardly directed tip 156.

The gears 140 and 150, and the arm 148 are positioned to one side of the path of travel of the box blank, and the rest position of the shaft 152 and flap folding arm 154, as shown in dotted lines in Fig. 13, is such that the end wall 30 and end flap 32 can be moved up without engaging these parts. A torsion spring (not shown) acts between the planet gear 150 and the arm 148 to resist rotation of the gear 150. Accordingly, when the sun gear 140 is pivoted by the connecting rod 144, the arm 148 rotates with the sun gear. When the arm 154 engages the flap 32, a resistance to further pivoting of the arm 148 is provided. In addition, a positive stop 158 preferably is provided on the depending arm 142. Pivoting of the arm 148 accordingly is arrested, and the planet gear 150 is therefore rotated in a counterclockwise direction as shown in the drawings. This causes the flap folding arm 154 to bend the flap 32 down from a vertical position as shown in Fig. 11, through the angular position of Fig. 13, and down to the folded position of Fig. 14, and preferably to the position of Fig. 15 where the flap is in close proximity to the end wall 30. Reverse rotation of the sun gear 140 causes the parts to move in the opposite direction back to their rest position.

The final operation on the box blank is illustrated in Figs. 12, 15 and 16. Substantially along the center line of the machine there is provided a clamp mechanism indicated generally at 158. There are two such mechanisms, as will be understood, one for cooperation with the front end of the box, and one for cooperation with the rear end. The one at the rear or left end is fixed in position, while the one at the front or right hand end is adjustable, by any suitable means such as a screw thread, to compensate for boxes of different lengths. It will be member 168 securedto, and depending from the bracket 162. Variationin spacing between the twojaw members accommodates differentthicknesses of box material, as will be understood. The jaw members 166 and 168 are respectively provided at their lower edges with clamping plates or flanges 170 and 172 extending transversely. A

hydraulic piston and cylinder mechanism 174 is connected between the arm 160 and the bracket 162 for bringing the jaws toward one another in clamping arrangement.

As will be understood, thejaws are positioned sufficiently high that the box blank will pass beneath them, including pivoting of the end flaps 32 thereof. The end flap 32 at each end'is left in close proximity to the corresponding end wall 30 by the mechanismdiscussed with regard to Figs. ll, 13 and 14, and the clamping jaws therefore readily pass on opposite sides of the end flaps *and end walls when the plate 126 is lowered by suitable mechanism (not shown).

Hydraulic actuation of the piston and cylinder device 174 causes the jaws to clamp toward one another, with the result that the transverse plates or flanges 170 and 172 press the end flaps against the end walls, the tabs 28 being secured between them. The box is now completed, and following raising of the clamp mechanism 158 by the plate 126, the box is engaged by the lug 56 on the final chain 48, and is moved from the machine to any suitable receiving or collecting apparatus or storage box.

It will now be apparent that I have disclosed a complete box forming machine having advantages of a continuous motion machine, and of an intermittent motion machine. The conveying mechanism moves continuously, thereby avoiding shocks and noises attendant upon intermittent motion machinery, whereas the box moves in termittently, thereby providing many advantages. Suflicient time is allowed for the glue to set so that the parts readily adhere to one another upon being brought into contact. In addition, relatively simple mechanisms are used to fold the parts of the box. These mechanisms are effective to over fold certain parts, and by acting on the box while it is stationary, bulging parts, or scraped surfaces are completely avoided. Accordingly, the machine is not only of superior quality, but produces a superior box as well.

Various changes in structure will no doubt occur to those skilled in the art, and will be understood as forming a part of this invention insofar as they fall within the spirit and scope of the appended claims.

The invention is claimed as follows:

1. A box forming machine comprising continuously movable conveyor means, means associated with said conveyor means for intermittently moving a box blank from one to another of a series of stations, said blank remaining stationary at each of said stations for a predetermined time means at one of said stations for folding sidewalls upwardly from said blank, means at another of said stations for folding side flaps downwardly against said sidewalls to form double thickness sidewalls, means at a further one of said stations for folding end tabs on said sidewalls into confronting relation with one another, means at a station no earlier in sequence than the last mentioned station for folding end walls upwardly into proximity with said end tabs, and means at a station no earlier in sequence than the last mentioned station for folding end flaps downwardly on the opposite sides of said tabs and otherwise l into engagement with said end walls .for forming double thickness end walls.

from one to another of a series of stations, said blank remaining stationary for 'a predetermined timeat each of .said stations, 2. pluralityof box folding mechanisms respectively positioned-adjacent said series of stations for folding said blank while stationary into box form, the box folding mechanism at the final station comprising a sun gear, means pivotally mounting said sun gear, an arm disposed radially of said sun gear and coaxially pivotal therewith, a-planet gear rotatably carried by said arm and meshing with said sun gear, a shaft fixed to said planet gear for coaxial rotation therewith, a fo'lding member on said shaft and displaced axially from said planet gear, and means for rotating said sun gear whereby said planet gear, said shaft, and said folding member are pivoted as a unit -to bring said folding member into engagement with .afportion of a box blank, pivoting-of said arm thereupon being arrested and said planet gear being rotated by said sun gear to rotate said shaft and folding member to fold aportion of said blank back upon itself.

3. A box forming machine as set'forth in claim 2 wherein the mechanism at the final station further includes clamp means for clamping together the portion folded upon its elf.

4. In a box forming machine havingc onveyor means and a plurality of box folding mechanisms, a blank folding station comprising a rotatably mounted sun gear, an arm extending radially of said sun gear and co axially pivotal therewith, a planet gear rotatably carried by said arm and meshing with said sun gear, a shaft fixed on said planet gear for coaxial rotation therewith, a folding member fixed on said shaft and displaced axially from said planet gear, and means for rotating said sun gear whereby said arm, said planet gear, and said shaft and folding member are pivoted as a unit with said sun gear to bring said folding member into engagement with a box blank, whereupon movement of said arm is arrested and said sun gear rotates said planet gear to pivot said arm and said folding member, whereby to fold a portion of said blank back upon itself.

5. A box forming machine as set forth in claim 4 and further including clamp means operable upon the portion folded upon itself to clamp this portion firmly together.

6. A box forming machine comprising continuously movable conveyor means, means on said continuously movable conveyor means for intermittently moving a box blank from one to another of a series of blank folding stations, a pair of blank folding members on opposite sides of said conveyor means at one of said stations and pivotally mounted about horizontal axes parallel to said conveyor means, said blank folding members being pivotal from said substantial horizontal position upwardly and toward one another to form sidewalls of a box, substantially horizontal end folding members mounted at another of said stations for pivotal movement about axes transverse of said conveyor means, said end folding members being spaced longitudinally of said conveyor means, whereby pivoting of said end folding members from horizontal position upwardly and relatively toward one another forms endwalls of a box, four vertical posts at one of said stations, and a tab folding member on each of said posts whereby pivoting of said posts folds tabs at the ends of the sidewalls into confronting relation whereby to be in proximity with endwalls of the box.

7. A box forming machine comprising continuously movable conveyor means, means on said continuously movable conveyor means for intermittently moving a box blank from one to another of a series of blank folding stations, a pair of blank folding members on opposite sides of said conveyor means at one of said stations and pivotally mounted about horizontal axes parallel to said conveyor means, said blank folding members being pivotal from said substantial horizontal position upwardly and toward one another to form sidewalls of a box, substantially horizontal end folding members mounted at another of saidystations for pivotal movement aboutaxes transverse of said conveyor means, said end folding members being spaced longitudinally of said conveyor means, whereby pivoting of said end folding members from horizontal position upwardly and relatively toward one another forms endwalls of a box, a plurality of shaft means at one of said stations, and four tab folding members in rectangularly spaced relation on said shaft means whereby pivoting of said shaft means folds tabs at the ends of the sidewalls into confronting relation whereby' to be in proximity with endwalls of the box.

8. A box forming machine comprising conveyor means for moving box blanks and a succession of folding means for folding said box blanks into box form, said folding means being positioned adjacent said conveyor means so as to act on each successive blank in the following sequence, means for folding sidewalls upwardly from said blank, means for folding side flaps downwardly against said sidewalls to form double thickness sidewalls, means for folding end tabs on said sidewalls into confronting relation with one another, means for folding end walls upwardly into proximity with said end tabs, and means for folding end flaps downwardly into engagement with said end walls to form double thickness end walls, said end tabs being trapped between said end walls and said end flaps by the last mentioned folding means, said sequence of folding means acting on said blank while said blank occupies a plurality of positions along said conveyor. t

9. A box forming machine comprising conveyor means for moving box blanks and a succession of folding means for folding said box blanks into box form, said folding means being positioned adjacent said conveyor means so as to act on each successive blank in the following sequence, means for folding side flap portions into engagement with sidewall portions to form double thickness sidewalls, means for folding said double thickness sidewalls upwardly from the remainder of said blank, means for folding end tabs on said sidewalls into confronting relation with one another, means for folding end walls upwardly into proximity with said end tabs, and means for folding end flaps downwardly into engagement with said end walls to form double thickness end walls, said end tabs being trapped between said end walls and said end flaps by the last mentioned folding means, said sequence of folding means acting on said blank while said blank occupies a plurality of positions along said conveyor.

References Cited in the file of this patent UNITED STATES PATENTS 2,125,147 Bergstein July 26, 1938 2,279,534 Sidebotham et a1. Apr. 14, 1942 2,541,914 Conser Feb. 13, 1951 2.710,566 Ahlmeyer et al. June 14. 1955 

